Convective Cooling Devices and Methods for Cooling Housings

ABSTRACT

A cooling device includes a body formed into an elongate strip having upper and lower surfaces. The elongate strip is configured to contact the housing along the lower surface for conductive heat transfer from the housing to the body. Each of a plurality of cooling fins is attached to the strip and extends from one end attached to the upper surface of the strip another, free end. The device includes a first tab disposed at one end of the elongate strip, and a second tab disposed at another end of the elongate strip. The elongate strip is made from a compliant material such that the elongate strip conforms to a shape of the housing when the first and second tabs are connected to the housing and a majority of the lower surface contacts the housing. The fins are arranged to convectively dissipate heat from the body.

TECHNICAL FIELD

The present disclosure relates to cooling of equipment generating heatwithin enclosed housings, and, more particularly, to securement ofcooling fins on exterior surfaces of heat generating equipment housingsand methods of assembly thereof.

BACKGROUND

Many types of heat generating equipment operating inside of housings(e.g., gear reducers) are thermally limited due to internal lossesgenerating heat. Cooling systems become important add-ons to achievecompetitive power densities for at least some known heat generatingequipment operating inside housings. The dominant effect that limits theachievable overall heat transfer (e.g., by cooling) of a gear reducer,for instance, is the convection at the outer housing surfaces.Convection can be increased with forced airflow around the housings orextended surfaces known as fins.

The incorporation of fins onto housings to improve cooling has beenproposed in the past, for example, by casting cooling fins into thecasing itself. However, while cast fins may improve cooling of thehousing, their effectiveness (fin efficiency) is limited. In the case ofcast iron housings with cast iron fins, fin efficiency is particularlylow as compared to those made from, for instance, aluminum, which has agreater thermal conductivity than cast iron. Furthermore, cast finsincluded on housings adds weight to the housing, and increases thepackaging envelope of the housing.

SUMMARY OF THE DISCLOSURE

One aspect of the disclosure is a convective cooling device configuredfor attachment to a housing The convective cooling device includes,comprising a body shaped as an elongate strip. The body includes upperand lower surfaces extending along a longitudinal axis. The body isconfigured to contact the housing along the lower surface for heattransfer from the housing to the body. The convective cooling deviceincludes a plurality of cooling fins attached along the upper surface.Each of the plurality of elongate fins are connected to the uppersurface of the elongate strip at one end, and they extend away from theupper surface of the elongate strip at another, free end. The convectivecooling device includes a first tab disposed at one end of the elongatestrip, and a second tab disposed at another end of the elongate strip.The body is made from a compliant material such that the body conformsto a shape of the housing when the first and second tabs are connectedto the housing and a majority of the lower surface contacts the housing.The fins are arranged to dissipate heat from the body.

Another aspect of the disclosure is a convective cooling arrangement fora housing. The convective cooling arrangement includes a housing havingan exterior surface. The convective cooling arrangement includes one ormore heat sinks. Each of the one or more heat sinks includes a generallyflat body having a plate shape. The generally flat body includes upperand lower surfaces. The generally flat body of each of the one or moreheat sinks is connected to the exterior surface of the housing andconfigured to conductively absorb heat from the housing. The convectivecooling arrangement includes a plurality of cooling fins attached alongthe upper surface of each of the one or more heat sinks. Each of theplurality of cooling fins are connected to the upper surface of each ofthe one or more heat sinks and extending away from the upper surface.The convective cooling arrangement includes at least one fastenerdisposed to fasten at least one of the one or more heat sinks to thehousing.

Yet another aspect of the disclosure is a method for cooling a housing.The method includes providing a heat sink having a body, the bodyincluding upper and lower surfaces. The method includes thermallyattaching the lower surface of the body to an exterior surface of thehousing. The step of thermally attaching the body to the housingincludes deforming the body such that the body conforms to a shape ofthe housing. The method includes conductively cooling the housing byabsorbing heat into the body. The method includes providing a pluralityof fins arranged along the upper surface of the body. Each of theplurality of elongate fins is connected to the upper surface of the bodyat one end, and they extend away from the upper surface of the body atanother, free end. The method includes convectively dissipating heatfrom the body through the fins.

Further and alternative aspects and features of the disclosed principleswill be appreciated from the following detailed description and theaccompanying drawings. As will be appreciated, the principles related toaddition of cooling systems and methods of cooling equipment disclosedherein are capable of being carried out in other and differentembodiments, and capable of being modified in various respects.Accordingly, it is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and do not restrict the scope of the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a convective cooling device according to anembodiment of the disclosure.

FIG. 2 is a side view of an output side of a gearbox housing.

FIG. 3 is a side view of a convective cooling device according to anembodiment of the disclosure.

FIG. 4 is a side view of a convective cooling device according to anembodiment of the disclosure superimposed on a side view of an inputside of the gearbox housing shown in FIG. 2.

FIG. 5 is a side view of the convective cooling device shown in FIG. 4attached to the gearbox housing shown in FIG. 2 according to anembodiment of the disclosure.

FIG. 6 is a side view of a convective cooling device according to anembodiment of the disclosure superimposed on a side view of the outputside of the gearbox housing shown in FIG. 2.

FIG. 7 is a side view of the convective cooling device shown in FIG. 6attached to the gearbox housing shown in FIG. 2 according to anembodiment of the disclosure.

FIG. 8 is a perspective view of a convective cooling device attached toa gearbox housing according to an embodiment of the disclosure.

FIG. 9 is a perspective view of the convective cooling device shown inFIG. 8 attached to the gearbox housing shown in FIG. 8 according to anembodiment of the disclosure.

FIG. 10A is a cross sectional view of a convective cooling deviceattached to a gearbox housing according to an embodiment of thedisclosure.

FIG. 10B is a magnified cross sectional view of the convective coolingdevice shown in FIG. 10A attached to the gearbox housing shown in FIG.10A according to an embodiment of the disclosure.

FIG. 11A is a cross sectional view of a convective cooling deviceattached to a gearbox housing according to an embodiment of thedisclosure.

FIG. 11B is a perspective and partial cross sectional view of theconvective cooling device shown in FIG. 11A attached to the gearboxhousing shown in FIG. 11A according to an embodiment of the disclosure.

FIG. 12 is a side and partial cross sectional view of a convectivecooling device attached to a gearbox housing according to an embodimentof the disclosure.

FIG. 13 is a perspective view of a heat sink attached to the gearboxhousing shown in FIG. 8 and FIG. 9 according to an embodiment of thedisclosure.

FIG. 14A is a perspective view of a heat sink showing a bottom surfacethereof according to an embodiment of the disclosure.

FIG. 14B is a top view of the heat sink shown in FIG. 14A.

FIG. 15 is a flowchart of a method for cooling a housing according to anembodiment of the disclosure.

FIG. 16 is a flowchart of an aspect of the thermally attaching step ofthe method shown in FIG. 15 according to an embodiment of thedisclosure.

FIG. 17 is a flowchart of an aspect of the conductively cooling step ofthe method shown in FIG. 15 according to an embodiment of thedisclosure.

FIG. 18 is a flowchart of a method for cooling a housing according to anembodiment of the disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments orfeatures, examples of which are illustrated in the accompanyingdrawings. Wherever possible, corresponding or similar reference numberswill be used throughout the drawings to refer to the same orcorresponding parts. Moreover, references to various elements describedherein, are made collectively or individually when there may be morethan one element of the same type. However, such references are merelyexemplary in nature. It may be noted that any reference to elements inthe singular may also be construed to relate to the plural andvice-versa without limiting the scope of the disclosure to the exactnumber or type of such elements unless set forth explicitly in theappended claims.

FIG. 1 is a side view of a convective cooling device 1 according to anembodiment of the disclosure. The convective cooling device 1 includes abody of a heat conductive material formed into an elongate strip 3having upper (“U”) and lower (“L”) surfaces extending along alongitudinal axis 19. The convective cooling device 1 includes aplurality of cooling fins 24 attached along at least a portion of theupper surface U of the elongate strip 3. In an embodiment, the pluralityof cooling fins 24 are elongate fins 24. Each of the plurality ofelongate fins 24 is connected to the upper surface U of the elongatestrip 3 at one end (e.g., a first fin end 23 proximal a base 22 of theelongate strip 3). Each of the plurality of elongate cooling fins 24extends away from the upper surface U of the elongate strip 3 atanother, free end (e.g., a second fin end 25 distal the base 22). In anembodiment, the plurality of fins 24 is formed or attached along theupper surface U of the strip 3 transversely with respect to thelongitudinal axis 19 of the strip 3. The cross section of the fins 24can be rectangular, trapezoidal, or triangular. The fins can also beformed as cylinders that extend outward from the base 22. In anembodiment, at least a portion of the strip 3 includes the plurality offins 24 in thermal contact with the base 22 to allow heat transfer fromthe base 22 to an outer surface 26 of the cooling fins 24.

The convective cooling device 1 includes a first tab 8 a disposed at oneend (e.g., a first end 4) of the elongate strip 3. The convectivecooling device 1 includes a second tab 8 b disposed at another end(e.g., a second end 6 opposite the first end 4) of the elongate strip 3.In an embodiment, at least one of the first end 4 and the second end 6of the strip 3 includes an outward tapered tip 28, but in alternativeembodiments, the first end 4 or the second end 6 of the strip 3 caninclude an inward tapered tip 30, or a square or rectangular tip 31(see, e.g., FIG. 4).

Referring to FIG. 2, a side view of an output side of a gearbox housing2 is shown. In this embodiment, the base 22 of the elongate strip 3extends between the first end 4 and the second end 6. The first tab 8 ais formed at an angle, A, relative to a plane 10 a defined by a portionof the elongate strip 3 adjacent the first tab 8 a. As shown, in FIG. 1,the plane 10 a is parallel to the longitudinal axis 19 when the elongatestrip 3 is laid flat. The second tab 8 b is formed at an angle, A′,relative to a plane 10 b defined by a portion of the elongate strip 3adjacent the second tab 8 b. The plane 10 b is parallel to thelongitudinal axis 19 when the elongate strip 3 is laid flat. In theillustrated embodiment, the first tab 8 b at the first end 4 forms theangle A relative to its adjacent plane 10 a that is equal to the angleA′ formed by the second tab 8 b at the second end 6 relative to itsadjacent plane 10 b, but it should be appreciated that the angles A andA′ may be different. Either (or both) of the angles A and A′, dependingon the requirements of a particular installation, may be an acute,obtuse, or right angle, and may even be formed at zero (or 180) degreesrelative to any adjacent straight sections of the elongate strip.

The gearbox housing 2 shown in FIG. 2 includes a shell 14 enclosing acavity 16. An exterior surface 20 of the housing 2 faces, and may beexposed to, an external ambient environment 32, which may be at leastpartially enclosed from the outdoors. In an embodiment, the shell 14includes an interior surface 18 facing the cavity 16. During operation,heat-generating equipment 12 is positioned inside the cavity 16. In theembodiment shown in FIG. 2, the heat generating equipment 12 includesgears and the housing 2 is a gearbox housing, but any other mechanicalor electrical equipment can be housed within the housing 2. For example,the heat generating equipment 12 can include motors, generators,mechanical power transmissions, engines, turbines and turbomachinery,and housings for storing materials at high temperatures.

The housing 2 includes a base plate 22 in contact with a surface S(e.g., a floor) in the illustrated embodiment. During operation, theheat generating equipment 12 operating inside the housing 2 generatesheat. When the ambient environment 32 is at a lower temperature than thecavity 16 of the housing 2, heat may be transferred from the heatgenerating equipment 12, to the cavity 16 by convection, to the shell 14of the housing 2, also by convection, through the shell 14 byconduction, and to the ambient environment 32 by convection. Heattransfer occurring in this manner during operation may occur through oneor more heat transfer mechanisms including, without limitation,conductive, convective, and radiative heat transfer. In at least someknown housings 2, heat transfer from the inside to the exterior of thehousing 2 operates to cool the heat generating equipment 12 both duringoperation and after operation has ceased, in a condition sometimesreferred to as soakback.

FIG. 3 is a side view of a convective cooling device 1 a according to anembodiment of the disclosure. The convective cooling device 1 a shown inFIG. 3 includes the features described above in detail with reference toFIG. 1. In the embodiment shown in FIG. 3, the first 4 and second 6 endsof the elongate strip 3 include the square tip 31. Also, in theembodiment shown in FIG. 3, the second fin end 25 of at least one of theplurality of cooling fins 24 has a rounded, rather than square orrectangular (as shown in FIG. 1) cross-sectional profile, as does thestrip 3. Of course, rounded or differently-shaped fins may also be used,for example, where the convective cooling device 1 a is frequentlycontacted by workers (by their hands or other parts of their bodies) ina facility, or where exposure to dirt requires a different fin shapethat accumulates less dirt, or when air flow around the fins can beimproved with a different shape. In the embodiment shown in FIG. 3, theangle A and the angle A′ are both 0°. The convective cooling device 1 aassumes a U-shape, as by being bent into the U-shape, by being extrudedinto the U-shape, by being stamped into the U-shape, and/or by employingother or additional useful forming and shaping operations, includingmanual bending by an installer, and other techniques as is known for acustom installation. The convective cooling device 1 a can also bemanufactured as having a U-shape in the first place or to any othersuitable shape for the corresponding shape of the housing. The shapingof the convective cooling device is tailored to a corresponding shape ofa housing onto which the cooling device is fitted or installed. Ingeneral, the shape and/or additional dimensions of the convectivecooling device 1 a may be predetermined by a user of the device 1 abased on dimensions of the particular housing 2 for which the device 1 ais to be used. Forming and/or shaping the convective cooling device 1 ain this manner may facilitate later installation, assembly, and similarsteps as described in further detail herein.

FIG. 4 is a side view of a convective cooling device 1 b according to anembodiment of the disclosure superimposed on a side view of an inputside of the gearbox housing 2 shown in FIG. 2 before installation, andFIG. 5 is a side view of the convective cooling device 1 b shown in FIG.4 attached to the gearbox housing 2 shown in FIG. 2 after installation.In the embodiments shown in FIG. 4 and FIG. 5, the convective coolingdevice 1 b assumes a generally U-shape, but with an introduced overbendbeyond the U-shape shown in FIG. 4. In the overbent shape, the elongatestrip 3 with cooling fins 24 of the convective cooling device 1 b is ina relaxed state and has a width between the first 4 and second 6 endsthat is less than a width of the housing 2 proximate the base plate 22.

As shown in FIG. 4, the dimensions of the convective cooling device 1 band the values of angle A and angle A′ are predetermined based on thedimensions and/or contours of the housing 2 shown in FIGS. 4 and 5. Inan embodiment, the first 8 a and second 8 b tabs of the convectivecooling device 1 b are bent at substantially equal values of angle A andangle A′, respectively, to match, or at least approximate, the values ofthe angles with which base plate 22 meets the exterior surface 20 of thehousing 2. In the embodiment shown in FIGS. 4 and 5, the angle A and theangle A′ of the convective cooling device 1 b are both acute angles ofless than 90°.

As shown in FIG. 5, the convective cooling device 1 b may be elasticallydeformed to open up and fit around the housing 2. In an embodiment, thewidth between the first 4 and second 6 ends in the relaxed state may beincreased to a value that is substantially equal to the width of thehousing 2 proximate the base plate 22. Increasing the width between thefirst 4 and second 6 ends of the device 1 b in the relaxed stateintroduces a spring-like state in the device 1 b. In addition to orinstead of forming and/or shaping the device 1 b to match or at leastapproximate the dimensions, angles, and contours of the housing 2, thisspring-like state introduced by increasing the width between the first 4and second 6 ends of device 1 b may facilitate the device conforming tothe contours of the housing 2.

The convective cooling device 1 b attached to the housing 2 as shown inFIG. 5 has the lower surface L of the strip 3 positioned on the shell 14with the base 22 in thermal contact with the exterior surface 20 andconforming to a contour thereof. In an embodiment, the thermal contactof the device 1 b body lower surface L of the strip 3 and the conformingof the strip 3 with the contour of the exterior surface 20 of thehousing 2 is facilitated by securing at least a portion of the device 1b to at least a portion of the housing 2. In an embodiment, the elongatestrip 3 is configured to contact the housing 2 along the lower surface Lfor conductive heat transfer from the housing 2 to the body (e.g., thebase 22). Securing the convective cooling device 1 b to the housing 2after attaching the device 1 b to the housing 2 to conform to thecontours of the housing 2 facilitates the transfer of heat from theshell 14 of the housing 2 to the base 22 of the elongate strip 3.

As shown in FIG. 5, the first 8 a and second 8 b tabs are utilized forsecuring the elongate strip 3 to the housing 2 at each of the first 4and second 6 ends, respectively. In the present embodiment, the first 8a and second 8 b tabs include a tab bore 13 formed therethrough thataccommodates a fastener 17. A portion of the housing 2 includes acorresponding threaded bore 15 that threadably engages the fastener 17.In the embodiment shown in FIG. 5, the housing 2 includes a threadedbore 15 on the base plate 22 of the housing 2 positioned on each sidethereof. The base plate 22 may function as a gearbox-mounting flange,and the fastener 17 inserted through each pair of tab bores 13 andhousing bores 15 may be used to simultaneously fasten the convectivecooling device 1 b to the housing 2 and the housing 2 to the surface S.As shown, the first 8 a and/or the second 8 b tabs of the elongate strip3 may be secured to the housing 2 (e.g., at the base plate 22) using aweld, either instead of or in addition to the fastener 17. Optionally,to improve the securement of the convective cooling device 1 b onto thehousing 2, additional fastening sites along the elongate strip 3 may beused.

The elongate strip 3 may be made from a compliant material such that theelongate strip 3 conforms to the contours and/or shape of the housing 2when the first 8 a and second 8 b tabs are connected to the housing 2and a majority of the lower surface L contacts the housing 2. Thecompliant material of construction of the disclosed convective coolingdevices may be elastically and/or plastically deformable to facilitateattachment and conforming to the contours and/or shape of the housing 2,as described above with reference to FIGS. 4 and 5. In one embodiment,the material of construction of the plurality of fins 24 and the base 22of the body of the convective cooling devices described herein are thesame, and these structures are unitarily or integrally formed. Forexample, the convective cooling devices disclosed herein are made ofaluminum or an aluminum alloy such as aluminum alloy 6061 with T6 heattreatment, or aluminum alloy from the 1000 class, but other materialsmay be used, for example, copper or a copper alloy. The material ofconstruction of the disclosed convective cooling devices may bedifferent from the material of construction of the housing 2 (e.g., thematerial(s) of construction of the shell 14 and/or exterior surface 20of the housing 2), which may be made from iron or an iron alloy such asASTM A48 class 30 gray cast iron.

During operation, the convective cooling device 1 b attached to thehousing 2 receives the generated heat by conduction, for example, fromthe shell 14 of the housing 2. The heat received into the base 22 flowsfrom the base 22 to the plurality of cooling fins 24 by, for example,conduction. The heat received into the plurality of fins 24 is thentransferred to the ambient environment 32 through the fin outer surfaces26. Heat transfer from the plurality of fins 24 to the ambientenvironment 32 can occur through radiation, forced convection, freeconvection, or any combination of those mechanisms. In one contemplatedarrangement, one or more air flow systems 33 (three are shown in FIG. 5)such as a fan may be positioned proximate the housing 2 with attachedconvective cooling device 1 b to facilitate heat flow from the pluralityof fins 24 to the ambient environment 32 by directing an air flow (“F”)onto at least a portion of the plurality of fins 24. As compared to theheat transfer mechanisms shown and described above with reference toFIG. 2, heat transfer rates occurring in the presence of the disclosedconvective cooling devices attached to housings 2 are higher, andtherefore achieve better cooling effects (e.g., as compared to cast ironhousings with cast fins of the material as the housing) for the heatgenerating equipment 12 in the housing 2 during and/or after itsoperation.

FIG. 6 is a side view of a convective cooling device 1 c according to anembodiment of the disclosure superimposed on a side view of the outputside of the gearbox housing 2 shown in FIG. 2. FIG. 7 is a side view ofthe convective cooling device 1 c shown in FIG. 6 attached to thegearbox housing 2 shown in FIG. 2 according to an embodiment of thedisclosure. In the embodiments shown in FIG. 6 and FIG. 7, theconvective cooling device 1 c assumes a generally U-shape, but with anunderbend which increases the width between the first 4 and second 6ends as compared to the convective cooling device 1 b shown in FIG. 4.In the underbent shape, the elongate strip 3 with cooling fins 24 of theconvective cooling device 1 c is in a relaxed state and has a widthbetween the first 4 and second 6 ends that is greater than a width ofthe housing 2 proximate the base plate 22.

As shown in FIG. 6, the dimensions of the convective cooling device 1 cand the values of angle A and angle A′ are predetermined based on thedimensions and/or contours of the housing 2 shown in FIGS. 6 and 7. Inan embodiment, the first 8 a and second 8 b tabs of the convectivecooling device 1 b are not bent relative to the adjacent planes (10 a,10 b) and thus the tabs (8 a, 8 b) have values of angle A and angle A′,respectively, equal to or approximately 0°.

As shown in FIG. 7, the convective cooling device 1 c in its relaxedstate may be fit onto the housing 2 without being elastically deformed.The width between the first 4 and second 6 ends in the relaxed state maybe decreased to a value that is at least approximately equal to thewidth of the housing 2 proximate the base plate 22. Decreasing the widthbetween the first 4 and second 6 ends of the device 1 b in the relaxedstate introduces a spring-like state in the device 1 c. In addition toor instead of forming and/or shaping the device 1 c to match or at leastapproximate the dimensions, angles, and contours of the housing 2, thisspring-like state introduced by decreasing the width between the first 4and second 6 ends of device 1 c may facilitate the device conforming tothe contours of the housing 2 by wrapping the elongate strip 3 aroundthe outer surface of the housing 2.

The convective cooling device 1 c attached to the housing 2 as shown inFIG. 7 has portions of the lower surface L of the elongate strip 3positioned on the shell 14 with the base 22 in thermal contact with theexterior surface 20 and conforming to a contour thereof. The thermalcontact of the device 1 c body lower surface L of the strip 3 and theconforming of the strip 3 with the contour of the exterior surface 20 ofthe housing 2 is facilitated by securing at least a portion of thedevice 1 c to at least a portion of the housing 2. The elongate strip 3is configured to contact the housing 2 along the lower surface L forconductive heat transfer from the housing 2 to the body (e.g., the base22). Securing the convective cooling device 1 c to the housing 2 afterattaching the device 1 c to the housing 2 to conform to the contours ofthe housing 2 facilitates the transfer of heat from the shell 14 of thehousing 2 to the base 22 of the elongate strip 3. Securing the device 1c to the housing in this manner may include elastically deforming thedevice 1 d from its relaxed state to facilitate the thermal contactbetween the lower surface L of the elongate strip 3 and the exteriorsurface 20 of the housing 2.

As shown in FIG. 7, the first 8 a and second 8 b tabs are utilized forsecuring the elongate strip 3 to the housing 2 at each of the first 4and second 6 ends, respectively. In the present embodiment, the first 8a and second 8 b tabs include the tab bore 13 formed therethrough toaccommodate a fastener 17. The housing 2 includes corresponding threadedbores 15 to threadably engage the fasteners 17. In the embodiment shownin FIG. 7, the housing 2 includes the housing bore 15 bored into, butnot through, the shell 14 of the housing 2. In another embodiment, notshown, the housing bore 15 is bored through the shell 14 of the housing2 on each side thereof and proximate the first 8 a and second 8 b ends.The first 8 a and/or the second 8 b tabs of the elongate strip 3 may besecured to the housing 2 using a weld, either instead of or in additionto the fasteners 17, and additional fasteners or other fastening methodsmay be used at other locations to secure the elongate strip 3 to thehousing 2.

FIG. 8 is a perspective view of a convective cooling device 1 d attachedto a gearbox housing 2 according to an embodiment of the disclosure. Theconvective cooling device 1 d shown in FIG. 8 is attached to the housing2 and conforms to the contours, angles, and/or shape of the housing 2,as described in detail above with respect to FIGS. 4 and 5. As shown inFIG. 8, the housing may include a frame rib 27 extending radiallyoutward from the shell 14 of the housing 2. The rib 27 may providestructural support for the housing 2 as, for example, to prevent or atleast mitigate excessive vibration during operation of gears and/orother rotating machinery inside housing 2. In the present embodiment,the first 8 a and/or the second 8 b tabs are formed at, or atapproximately right angles A and A′ relative to their respectiveadjacent planes 10 a and 10 b (only the first tab 8 a is shown in FIG.8). The right angle A of the first tab 8 a matches or at leastapproximates the angle with which base plate 22 meets the exteriorsurface 20 of the housing 2. In operation, the convective cooling device1 d effectuates cooling of the heat generating equipment 12 inside thehousing 2 by the same heat transfer mechanisms described in detail abovewith respect to FIG. 5.

FIG. 9 is a perspective view of the convective cooling device 1 d shownin FIG. 8 attached to the gearbox housing 2 shown in FIG. 7 according toan embodiment of the disclosure. In the embodiment shown in FIG. 9, twoconvective cooling devices 1 d are attached to the housing 2. In otherembodiments, not shown, three or more of the disclosed convectivecooling devices may be attached to a single housing 2. It is alsocontemplated that substantially an entire outer surface of the housingmay be covered by cooling devices disposed immediately adjacent to oneanother, or at a regular spacing. Attaching a plurality of the disclosedconvective cooling devices to one housing 2 may increase the speedand/or efficiency of heat transfer and thus improve cooling of the heatgenerating equipment 12 according to the disclosed devices and methods(e.g., as compared to attaching just one convective cooling device).

The convective cooling device 1 d attached to the housing 2 as shown inFIG. 8 has the lower surface L of the strip 3 positioned on the shell 14with the base 22 in thermal contact with the exterior surface 20 andconforming to a contour thereof. The thermal contact of the device 1 dbody lower surface L of the strip 3 and the conforming of the strip 3with the contour of the exterior surface 20 of the housing 2 isfacilitated by securing at least a portion of the device 1 d to at leasta portion of the housing 2. The elongate strip 3 is configured tocontact the housing 2 along the lower surface L for conductive heattransfer from the housing 2 to the body (e.g., the base 22). Securingthe convective cooling device 1 d to the housing 2 after attaching thedevice 1 d to the housing 2 to conform to the contours of the housing 2facilitates the transfer of heat from the shell 14 of the housing 2 tothe base 22 of the elongate strip 3.

As shown in FIGS. 8 and 9, the first 8 a and second 8 b tabs areutilized for securing the elongate strip 3 to the housing 2 at each ofthe first 4 and second 6 ends, respectively. In the present embodiment,the first 8 a and second 8 b tabs need not include the tab bore 13formed therethrough. A portion of the housing 2 includes the housingbore 15 to insert the fastener 17 through. In the embodiment shown inFIGS. 8 and 9, the housing 2 includes the housing bores 15 on the baseplate 22 of the housing 2 positioned on each side thereof.

In the present embodiment, the first 8 a and/or second 8 b tabs of theconvective cooling devices 1 d are secured to the housing 2 at its baseplate 22 by using clamping plates 50. The clamping plate 50 may be usedfor clamping the first 8 a and/or second 8 b tabs of the strip 3 to thehousing 2. As shown in FIG. 9, the clamping plate 50 is formed and/orshaped to match or at least approximate a shape of the housing 2, rib27, and/or base plate 22. The clamping plate 50 includes plate bores 51whose positions corresponds to the positions of the housing bores 15. Inthe present embodiment, the clamping plate includes a thin section 54,which accommodates the protrusion of the rib 27 onto the plane of thebase plate 22. The thin section 54 may be reinforced as, for example, byforming and/or shaping the clamp plate 50 to be thicker at and near thethin section 54 as compared to those portions of the clamp plate 50 nearthe plate bores 51 and near the ends of the clamp plate 50.

In the present embodiment, the base plate 22 may function as agearbox-mounting flange, and the fastener 17 inserted through each pairof plate 51 and housing 15 bores may be used to simultaneously fastenthe clamping plate 50 and device 1 d to the housing 2 and the housing 2to the surface S. Using the clamping plate 50 in the manner describedabove clamps the tabs (8 a, 8 b) of the elongate strip 3 between theexterior surface 20 of the housing 2 and the clamping plate 50, therebysecuring the device 1 d to the housing 2. The first 8 a and/or thesecond 8 b tabs of the elongate strip 3 may be secured to the housing 2(e.g., at the base plate 22) using a weld, either instead of or inaddition to using the fastener 17 and/or clamp plate 50. At least aportion of the elongate strip 3 is secured to at least a portion of thehousing 2 at strip 3 portions other than or addition to at the first 8 aand/or second 8 b tabs. In another embodiment, not shown, otherportion(s) of the elongate strip 3 instead of or in addition to the tabs(8 a, 8 b) may be secured to the housing 2 by clamping them theretousing the clamping plate 50. In yet another embodiment, not shown, theclamping of the tabs (8 a, 8 b) and/or other portion(s) of the strip 3is accomplished by welding the clamping plate 50 to the housing 2 eitherinstead of or in addition to otherwise securing the clamping plate 50 tothe housing 2.

FIG. 10A is a cross sectional view of a convective cooling device 1 eattached to a gearbox housing 2 according to an embodiment of thedisclosure. FIG. 10B is a magnified cross sectional view of theconvective cooling device 1 e shown in FIG. 10A attached to the gearboxhousing 2 shown in FIG. 10A according to an embodiment of thedisclosure. In the present embodiment, one or more base bores 40 areformed through the base 22 of the convective cooling device 1 e bodybetween one or more pairs of adjacent cooling fins 24. The base bores 40may include a counter bore 41 formed coaxially with the base bore 40. Apenetrating fastener 42 may be driven into the shell 14 of the housing 2through the base bore 40 to secure the elongate strip 3 of theconvective cooling device 1 e to the housing 2. Non-limiting examples ofpenetrating fasteners 42 include GRIPNAIL^((R)) MetalTack, PunchPin, andDriveTack.

In an embodiment, a diameter of the base bore 40 is greater than adiameter of a shaft 43 of the penetrating fastener 42, but is less thana head 44 of the penetrating fastener 42. This dimensional arrangementoff the base bore 40 and the penetrating fastener 42 enables metal burrs49 to form upon forcefully driving (e.g., using a pneumatic nailingtool) the penetrating fastener 42 into the housing 2. The metal burrs 49engage portions of the shaft 43 to facilitate a strong and long-lasting“bite” for securing the device 1 e to the housing 2. In anotherembodiment, not shown, the penetrating fastener 42 and the dimensionarrangements of the base bore 40 and the penetrating fastener 42 may beemployed for securing the tabs (8 a, 8 b) to the housing 2 using, forexample, counterbored tab bores 13. Use of the penetrating fasteners 42for securing the disclosed convective cooling devices to the housing 2is advantageous in certain applications of the disclosed devices andsystems because it does not require positioning, predrilling and/orthreading holes into the housing 2.

FIG. 11A is a cross sectional view of a convective cooling device ifattached to a gearbox housing 2 according to an embodiment of thedisclosure. FIG. 11B is a perspective and partial cross sectional viewof the convective cooling device if shown in FIG. 11A attached to thegearbox housing 2 shown in FIG. 11A according to an embodiment of thedisclosure. In the present embodiment, one or more base bores 40 areformed through the base 22 of the convective cooling device if bodybetween one or more pairs of adjacent cooling fins 24. Thecorrespondingly coaxial housing bore 15 is threaded. As shown in FIG.11B, the base bore 40 may be formed as a slotted hole. A threaded screwor bolt 52 may be inserted through the base bore 40 and into the housingbore 15 to secure the elongate strip 3 of the convective cooling deviceif to the housing 2. In another embodiment, not shown, the threadedscrew or bolt 52 may be employed for securing the tabs (8 a, 8 b) to thehousing 2 using, for example, the tab bores 13 with correspondinglycoaxial and threaded housing bores 15.

Also, as shown in FIG. 11B, a layer of thermal transfer compound 57 maybe applied to the lower surface L of the base 22 of the elongate strip 3prior to attaching and/or securing the disclosed convective coolingdevices to the housing 2. To facilitate heat transfer from the housing 2through the shell 14 and to the base 22 of the strip 3, embodiments ofthe disclosed convective cooling devices may include thermal transfercompound 57 in contact with the base 22 of the strip 3 in contact withthe exterior surface 20 of the housing 2. In another embodiment, notshown, the thermal transfer compound 57 includes an adhesive tofacilitate securing the disclosed convective cooling devices to thehousing 2. To facilitate securing the disclosed convective coolingdevices to the housing 2, embodiments of the disclosed convectivecooling devices may include an adhesive, not shown, in contact with thebase 22 of the strip 3 in contact with the exterior surface 20 of thehousing 2, and either instead of or in addition to using the thermaltransfer compound 57.

FIG. 12 is a side and partial cross sectional view of a convectivecooling device 1 g attached to a gearbox housing 2 according to anembodiment of the disclosure. The convective cooling device 1 g mayinclude the base bore(s) 40, as described above with reference to FIGS.11A and 11B. The housing 2 may include a threaded mounting stud 58coupled to the housing 2 at the exterior surface 20 thereof via a weld59. The material of construction of the housing 2 shell 14 is the sameas the material of construction of the mounting stud 58. In anotherembodiment, the stud 58 and the shell 14 of the housing 2 areconstructed of different materials. Mounting studs 58 can be welded tothe housing 2 using a stud welder based on arc welding or frictionwelding (e.g., RAMSTUD® Friction Welding System). Both welding methodscan join similar or dissimilar metals. Friction welding can be donethrough layer(s) of paint on the exterior surface 20 of the housing 2.

In the present embodiment, one or more base bores 40 are formed throughthe base 22 of the convective cooling device 1 g body between one ormore pairs of adjacent cooling fins 24. The base bore 40 may be formedas a slotted hole, as shown in FIG. 11B. The threaded mounting stud 58may be inserted through the base bore 40 and the device 1 g may besecured to the housing 2 by threading and tightening a nut 68 onto thethreaded mounting stud 58. In the illustrated embodiment, a washer 61 isplaced on the mounting stud 58 to contact the upper surface U of thestrip 3 and the nut 68. In another embodiment, not shown, a washer 61 isplaced on the mounting stud 58 to contact the lower surface L of thestrip 3 and the exterior surface 20 of the housing 2, either instead ofor in addition to the aforementioned washer 61 arrangement. In yetanother embodiment, not shown, the threaded mounting stud 58 may beemployed for securing the tabs (8 a, 8 b) to the housing 2 using, forexample, the tab bores 13 with correspondingly coaxial and threadedmounting studs 58.

The disclosed convective cooling devices may be secured to the housing 2using any combination of the components and methods described herein.For example, the first 8 a and/or the second 8 b tab may be secured tothe housing 2 using a fastener 17, the mounting stud 58, and/or a weld.

FIG. 13 is a perspective view of a convective cooling arrangement 72 forthe gearbox housing 2 shown in FIG. 8 and FIG. 9 according to anembodiment of the disclosure. The convective cooling arrangement 72includes one or more heat sinks 60. Each of the one or more heat sinks60 includes a generally flat body 62 having a plate shape. The body 62includes upper 64 and lower 67 surfaces. The body 62 of each of the oneor more heat sinks 60 is connected to the exterior surface 20 of thehousing 2 and configured to conductively absorb heat from the housing 2.A plurality of cooling fins 69 are attached along the upper surface 64.Each of the plurality of elongate cooling fins 69 are connected to theupper surface 64 of the body 62 at one fin end, and extends away fromthe upper surface 64 of the body 62 at another, free fin end. The freefin ends of at least some of the plurality of cooling fins 69 can takeon any appropriate shape.

The convective cooling arrangement 72 includes at least one fastener 75disposed to fasten at least one of the one or more heat sinks 60 to thehousing 2. In the embodiment shown in FIG. 13, the fastener 75 is a hoopclamp strip fastener 75. In the present embodiment, the one or more heatsinks 60 include fin extrusions positioned on the shell 14 of thehousing 2 in thermal contact with the exterior surface 20 and clampedthereto by the hoop clamp strip fastener 75 with its end 78 clamped tothe housing 2 by clamping plates 50, substantially as shown anddescribed above with reference to clamping tabs (8 a, 8 b) to thehousing using clamping plate 50.

FIG. 14A is a perspective view of a heat sink 60 showing a lower surface67 thereof according to an embodiment of the disclosure. FIG. 14B is atop view of the heat sink 60 shown in FIG. 14A. The heat sink 60 shownin FIGS. 14A and 14B includes the features described above withreference to FIG. 13. Additionally, in the present embodiment, the heatsink 60 includes channels 81 for distribution of thermal transfercompound 57 in the base 62 of the heat sink 60 (e.g., a base 62 of theheat sink 60 body). As shown in FIG. 14A, the channels 81 are formed inthe lower surface 67 of the base 62. In the present embodiment, thechannels 81 have a through- and/or V-shaped cross section.

The heat sink 60 may include a grease fitting 82. The grease fitting 82may include a ball check valve. In the present embodiment, the greasefitting 82 extends from the upper surface 64 of the heat sink 60 throughthe base 62 to an outlet 83 in fluid communication with the greasefitting 82 and positioned on the lower surface 67 of the base 62. In thepresent embodiment, the grease fitting 82 is positioned at leastapproximately at a center of the heat sink 60 upper surface 64 and theoutlet 83 is positioned at least approximately at a center of the heatsink 60 lower surface 67. In another embodiment, not shown, the greasefitting 82 and/or the outlet 83 is positioned at a location other thanthe center of the upper 64 and/or lower 67 surfaces. In yet anotherembodiment, not shown, the heat sink 60 may include a plurality ofgrease fittings 82 and/or a plurality of outlets 83. Collectively, thechannels 81, the one or more grease fittings 82, and the one or moreoutlets 83 form a channel set.

In an embodiment, thermal transfer compound 57 may be flowed into thegrease fitting 82 after the heat sink 60 has been attached and/orsecured to the housing 2 as, for example, described above with referenceto FIG. 13. By flowing the thermal transfer compound 57 under pressurethrough the grease fitting 82, the thermal transfer compound 57 willsubsequently flow into the channels 81, thereby forming a layer ofthermal compound 57 between the lower surface 67 of the heat sink 60 andthe exterior surface 20 of the housing 2 as, for example, describedabove with reference to FIG. 11B. Upon cessation of flowing the thermaltransfer compound 57 under pressure through the grease fitting 82, theball check valve closes to keep out dirt and other contaminants from thelayer of thermal transfer compound 57. The present embodiment of theheat sink 60 is advantageous for use in the cooling arrangement 72 shownin FIG. 13. For example, the flowing of the thermal transfer compound 57through the grease fitting 82 eliminates, or at least reduces, theoccurrence of air pockets between the lower surface 67 of the heat sink60 base 62 and the exterior surface 20 of the housing 2. Additionally,the present embodiment of the heat sink 60 is advantageous for coolingarrangement 72 because the thermal transfer compound 57 may be renewedfrom time to time it dries out.

In another embodiment, not shown, the disclosed convective coolingdevices may include one or more channel sets. For example, and withoutlimitation, the convective cooling device 1 shown in FIG. 1 may includethe channels 81 formed in the lower surface L of the base 22. Theconvective cooling device 1 may include the grease fitting 82 extendingfrom the upper surface U of the strip 3 base 22 to an outlet 83 in fluidcommunication with the grease fitting 82 and positioned on the lowersurface L of the base 22. In such embodiments of the disclosedconvective cooling devices, including the one or more channel sets isadvantageous for use in cooling housings 2. For example, the flowing ofthe thermal transfer compound 57 through the grease fitting 82eliminates, or at least reduces, the occurrence of air pockets betweenthe lower surface L of the strip 3 base 22 and the exterior surface 20of the housing 2. Additionally, including channel set(s) in thedisclosed convective cooling devices is advantageous for use in coolinghousings 2 because the thermal transfer compound 57 may be renewed fromtime to time it dries out.

FIG. 15 is a flowchart of a method 1000 for cooling a housing 2according to an embodiment of the disclosure. The method 1000 includesproviding 1002 a heat sink (e.g., convective cooling device 1 and/orheat sink 60) having a body, the body including upper and lowersurfaces. The method 1000 further includes thermally attaching 1004 thelower surface of the body to an exterior surface of the housing 2, wherethermally attaching 1004 the body to the housing 2 includes deforming1005 the body such that the body conforms to a shape of the housing 2.The method 1000 includes conductively cooling 1006 the housing 2 byabsorbing heat into the body, and providing 1008 a plurality of finsarranged along the upper surface of the body, each of the plurality ofelongate fins being connected to the upper surface of the elongate stripat one end, and extending away from the upper surface of the elongatestrip at another, free end. The method 1000 also includes convectivelydissipating 1010 heat from the body through the fins.

FIG. 16 is a flowchart of an aspect of the thermally attaching step 1004of the method 1000 shown in FIG. 15 according to an embodiment of thedisclosure. In the present embodiment, thermally attaching at 1004includes securing 1012 the heat sink to the housing 2, which includessecuring tabs at each end of the body to the housing 2.

FIG. 17 is a flowchart of an aspect of the conductively cooling step1006 of the method 1000 shown in FIG. 15 according to an embodiment ofthe disclosure. In the present embodiment, the conductively cooling step1006 includes transferring 1014 heat from a cavity 16 of the housing 2to the heat sink body.

FIG. 18 is a flowchart of a method 2000 for cooling a housing 2according to an embodiment of the disclosure. The method 2000 is appliedto cooling heat-generating equipment 12 contained in the housing 2. Themethod 2000 includes providing 2002 a convective cooling device 1including an elongate strip 3 of compliant material. In one embodiment,the strip 3 is provided with: a first end 4, a second end 6 opposite thefirst end 4, and tab (8 a, 8 b) at each of the first 4 and second 6ends, each end tab (8 a, 8 b) formed at an angle (A, A′) relative to aplane (10 a, 10 b) of the strip 3 adjacent the tab (8 a, 8 b).

The method 2000 includes securing 2004 at least a portion of the strip 3to a portion of the housing 2. Securing at 2004 includes securing eachtab (8 a, 8 b) of the strip 3 to a portion of the housing 2. The method2000 further includes thermally contacting 2006 at least a portion ofthe strip 3 with the housing 2, which in turn includes contacting alower surface L of a base 22 of the elongate strip 3 to the exteriorsurface 20 of the housing 2. The method 2000 also includes transferringheat at 2008 from the heat generating equipment 12 inside the cavity 16of the housing 2 to the base 22 of the elongate strip 3 through theexterior surface 20 of the shell 14, transferring heat at 2010 from thebase 22 of the elongate strip 3 to a plurality of cooling fins 24attached to the base 22, and transferring heat at 2012 from theplurality of cooling fins 24 to an ambient environment 32 outside thehousing 2.

It is contemplated that the material of construction of the disclosedconvective cooling devices may exhibit a temperature dependentcontraction when cooled from an elevated temperature that is beneath themelting point of the material of construction of the disclosedconvective cooling devices to an ambient or expected operatingtemperature. For example, the length (1) of the elongate strip 3 fromthe first 4 to the second 6 end is a value x centimeters (cm) when thematerial of construction is at a temperature (T) of A° C., where A° C.is less than the melting point. In the embodiment, the value of ldecreases to a value of y cm when T is decreased from A° C. to a valueof B° C.

The temperature dependent contraction may facilitate attachment andsecuring of the disclosed convective cooling devices to the housing 2 toachieve conformance to the contour and/or shape thereof and tofacilitate tight thermal attachment and contact between the lowersurface L of the disclosed convective cooling devices and the exteriorsurface 20 of the housing 2. For example, the tabs (8 a, 8 b) of theconvective cooling devices disclosed herein are secured to the housing(e.g., as shown in FIG. 5) while the device is at the elevatedtemperature T=A° C. Upon cooling to T=B° C., the attached and securedconvective cooling device contracts, resulting in a decrease in theend-to-end strip 3 length l from x cm to y cm.

Thus, methods 1000 and 2000 may include contracting steps (step 1016 andstep 2007, respectively). This contracting of the disclosed convectivecooling devices may stretch and/or elastically or plastically deform theelongate strip 3, at least locally, and enable tighter thermal contactand better cooling performance when used with housing 2 as compared toembodiments that do not attach and/or secure the strip 3 to housing 2 inthe elevated temperature state and then cool the strip 3 to the lowertemperature are attaching and securing it.

Various embodiments disclosed herein are to be taken in the illustrativeand explanatory sense, and should in no way be construed as limiting ofthe present disclosure.

While aspects of the present disclosure have been particularly shown anddescribed with reference to the embodiments above, it will be understoodby those skilled in the art that various additional embodiments may becontemplated by the modification of the disclosed machines, systems andmethods without departing from the spirit and scope of what isdisclosed. Such embodiments should be understood to fall within thescope of the present disclosure as determined based upon the claims andany equivalents thereof.

What is claimed is:
 1. A convective cooling device configured forattachment to a housing, comprising: a body shaped as an elongate strip,the body including upper and lower surfaces extending along alongitudinal axis, the body configured to contact the housing along thelower surface for heat transfer from the housing to the body; aplurality of cooling fins attached along the upper surface, each of theplurality of elongate fins being connected to the upper surface of theelongate strip at one end, and extending away from the upper surface ofthe elongate strip at another, free end; a first tab disposed at one endof the elongate strip, and a second tab disposed at another end of theelongate strip; wherein the body is made from a compliant material suchthat the body conforms to a shape of the housing when the first andsecond tabs are connected to the housing and a majority of the lowersurface contacts the housing; and wherein the fins are arranged todissipate heat from the body.
 2. The device of claim 1, wherein thefirst and the second tabs of the elongate strip are formed at an anglerelative to the body adjacent the first and second tabs, respectively.3. The device of claim 2, wherein the first tab forms the angle relativeto the first plane that is equal to the angle formed by the second tabrelative to the second plane.
 4. The device of claim 1, wherein thefirst tab forms the angle relative to the first plane that is not equalto the angle formed by the second tab relative to the second plane. 5.The device of claim 2, wherein the angle formed by at least one of thefirst and second tabs relative to its adjacent plane is an acute angle.6. The device of claim 2, wherein the angle formed by at least one ofthe first and second tabs relative to its adjacent plane is an obtuseangle.
 7. The device of claim 2, wherein the angle formed by at leastone of the first and second tabs relative to its adjacent plane is aright angle.
 8. The device of claim 1, wherein the plurality of coolingfins are transversely attached along the upper surface of the elongatestrip with respect to the longitudinal axis.
 9. The device of claim 1,wherein the body formed into the elongate strip has a U-shape, andwherein the elongate strip is elastically deformable to facilitate atleast one of attaching and securing the convective cooling device to thehousing.
 10. The device of claim 1, wherein the body is disposed in astretched state when installed onto the housing.
 11. A convectivecooling arrangement for a housing, comprising: a housing having anexterior surface; one or more heat sinks, each of the one or more heatsinks including a generally flat body having a plate shape, thegenerally flat body including upper and lower surfaces, wherein thegenerally flat body of each of the one or more heat sinks is connectedto the exterior surface of the housing and configured to conductivelyabsorb heat from the housing; a plurality of cooling fins attached alongthe upper surface of each of the one or more heat sinks, each of theplurality of cooling fins being connected to the upper surface of eachof the one or more heat sinks and extending away from the upper surface;and at least one fastener disposed to fasten at least one of the one ormore heat sinks to the housing.
 12. The arrangement of claim 11, whereinthe at least one fastener includes a hoop clamp extending substantiallyaround the housing.
 13. The arrangement of claim 12, wherein the hoopclamp is positioned over the one or more heat sinks and in contact withthe free end of at least some of the plurality of cooling fins, andwherein the one or more heat sinks are fastened to the housing by hoopclamp ends secured to the housing.
 14. The arrangement of claim 13,further comprising a clamping plate, wherein at least one of the hoopclamp ends is secured to the housing by an attachment to the clampingplate.
 15. The arrangement of claim 11, wherein the free end of at leastsome of the plurality of cooling fins is rounded.
 16. The arrangement ofclaim 11, further comprising a thermal transfer compound disposedbetween the lower surface of the heat sink body and the exterior surfaceof the housing.
 17. The arrangement of claim 16, wherein the one or moreheat sinks include channels formed in the lower surface of the heat sinkbody for distribution of the heat transfer compound in a base of theheat sink body.
 18. The arrangement of claim 17, wherein each of the oneor more heat sinks further includes: a grease fitting extending betweenthe upper and the lower surfaces of the heat sink body; and an outlet influid communication with the grease fitting and positioned on the lowersurface of the heat sink base.
 19. The arrangement of claim 11, whereineach of the one or more heat sinks comprises a plurality of heat sinks.20. A method for cooling a housing, comprising: providing a heat sinkhaving a body, the body including upper and lower surfaces; thermallyattaching the lower surface of the body to an exterior surface of thehousing, wherein thermally attaching the body to the housing includesdeforming the body such that the body conforms to a shape of thehousing; conductively cooling the housing by absorbing heat into thebody; providing a plurality of fins arranged along the upper surface ofthe body, each of the plurality of elongate fins being connected to theupper surface of the body at one end, and extending away from the uppersurface of the body at another, free end; and convectively dissipatingheat from the body through the fins.